Method and apparatus for making filamentous products



April 14, 1970 R. L.. JACKSON, JR.. EVAL 3,505,420

UCTS \\\\lllllllllllllll/lllf/ April 14, 1970 R. L. JACKSON, JR., TAL 3,506,420

/lll/ 26 3c -ma l ,y w MILFjymnr a. 2, Il!!! 611ml AH 'i 'i nml lll lll!! ll lll United States Patent O 3,506,420 METHOD AND APPARATUS FOR MAKING FILAMENTOUS PRODUCTS Robert L. Jackson, Jr., and Louis A. Kovreg, Louisville, Ky., assignors to American Air Filter Company, Inc., Louisville, Ky., a corporation of Delaware Filed Apr. 5, 1967, Ser. No. 628,762 Int. Cl. C03c 33/06, 37/10 U.S. Cl. 65-4 13 Claims ABSTRACT OF THE DISCLOSURE A method and apparatus for winding a curtain of separated filaments onto a rotating drum which provides collector means to urge filaments of selected portions of the filament curtain to mutually contiguous relation to form groups of filaments or multifilament strands which are wound on the rotating drum. The collector means include tapered sections to facilitate inserting the collector means into the filament curtain at selected times to form the filament groups. Also, the collector means can be rotated at selected speed so the peripheral speed of the surface is different than the linear speed at which filaments are drawn over the surface.

BACKGROUND OF THE INVENTION Previous apparatus for feeding a curtain of separated filaments to be wound on a rotating drum has in some instances included various means to collect selected numbers of individual filaments to form multifilament strands. Such previous collector means have included V-shaped guide means to draw a curtain of filaments to a common point to form a multifilament strand which can be collected on a rotating drum. Other collector means have included rotatable wheels disposed so the filaments are drawn along the cylindrical surface of the wheel so the lines of contact between the filaments and the wheel is parallel to the transverse axis of the wheel and, in most such arrangements, the wheel is mounted to rotate freely in response to the movement of the filaments over the surface so the speed of the peripheral surface of the wheel is substantially the same as the linear speed of draw of the filaments. In such previous arrangements where the line of contact between the surface of the collector wheel and the filaments falls generally parallel a transverse axis of the wheel, the path of the filaments is relatively narrow and, because of the abrasive nature of the filaments, grooves are normally cut into the surface of the wheel. Such grooves undesirably cause the filaments to break during operation and it is necessary to frequently resurface or smooth the surface of the guide means with resulting maintenance expense and decreased operating time.

In previous apparatus where rotating wheels have been used to collect separated filaments from a filament curtain to form multifilament groups it has neither been recognized nor has it been possible to alternately provide multifilament groups at selected locations along the width and intermediate the extremities of the filament curtain and separated filaments to be wound on the drum. In fact, in previous apparatus it is necessary to assemble the collectors to form such groups before operation is started and the apparatus cannot be modified during operation. While some other previous apparatus do provide means to alternately wind multifilament groups and separated filaments on the drum, the collector wheels are adapted for movement relative to the filament curtain and contact filaments only at the outer edges of the curtain so only two multifilament strands are formed, one at each end of the filter curtain. Heretofore, in winding a curtain of ice filaments onto a rotating drum in overlying layers it has neither been recognized nor has it been possible, Without stopping operation and adjusting the apparatus, to wind separated filaments onto the rotating drum during selected portions of the operating period and alternately form multifilament strands, including strands at selected locations along the width of the curtain, to be wound on the rotating drum during other selected portions of the operating period.

SUMMARY OF THE INVENTION The present invention provides a method and apparatus for winding a curtain of filaments onto a rotating drurn and forming multifilament groups or strands of filaments at selected locations along the width of the curtain by bringing a portion of the individual filaments into mutually contiguous contact on collector means. Within the scope of the present invention means are also provided to significantly reduce the effect of the abrasive action of the filaments on the collectors to prevent formation of narrow grooves in the collector surfaces.

Furthermore, the present invention provides a method and apparatus for winding a curtain of separated monofilaments onto a rotating drum during selected periods of the winding cycle and alternately winding multifilament groups, including groups formed at selected locations along the width of the curtain, onto the rotating drum during other selected periods of the winding cycle where it is not necessary to cease operation to change from one mode of operation to the other.

Various other features of the present invention will become obvious to one skilled in the art upon reading the disclosure set forth hereinafter.

More particularly, the present invention provides a method including: feeding a curtain of separated filaments from feeder means, winding the filaments onto a rotating drum, inserting collector means into the curtain to form multilament strands by urging separated filaments of the filament curtain to mutually contiguous relation and Winding such multiflament strands onto said rotating collector.

Furthermore, the present invention provides apparatus including a filament collector drum mounted for rotation about its longitudinal axis at selected speed, filament feeder means disposed to supply a curtain of filaments to be wound onto the rotating drum in overlying layers, and collector means to be inserted into the curtain of filaments at selected positions along the width of the curtain so filaments from a portion of the curtain are urged to mutual contact by the cylindrical surface to form multifilament strands to be wound on the rotating drum. The collector means can be disposed relative to the path of the filaments so the line of contact between the filaments and the surface is at an acute angle relative to the transverse axis of the collector means and the apparatus can further include means to rotate the collector so the speed of the surface at the area of contact between the filaments and the surface is different from the linear speed at which the filaments are drawn along the cylindrical surface.

It is to be understood that the description of one example of the present invention given herein is not by way of limitation and that various changes can be made in the arrangement, form, or configuration of the apparatus disclosed herein without departing from the scope or spirit and in the several steps of the method of the present inventon.

Referring to the drawing:

FIGURE 1 is an elevational view of a filament collecting apparatus in accordance with the present invention;

FIGURES 2a and 2b are reduced fragmentary views of winding apparatus illustrating one arrangement in accordance with the present invention, as hereinafter described;

FIGURE 3 is an enlarged sectional view taken along a plane passing through line 3 3 of FIGURE l;

FIGURE 4 is a view taken along a plane passing through line 4 4 of FIGURE 3 where for clarity the filament curtain of FIGURE 3 is not shown;

FIGURE 5 is a view taken along a plane passing through line 5 5 of FIGURE 3;

FIGURE 6 shows an example of a cylindrical filament collector in accordance with the present invention;

FIGURE 7 is a view illustrating the use of collector means as shown in FIGURE 6;

FIGURE 8 is another View illustrating the use of an example of a collector means shown in FIGURE 6;

FIGURE 9 is a fragmentary elevational view showing the use of an example of another type of collector in accordance with the present invention;

FIGURE l0 is an enlarged fragmentary View showing an example of such other collector means of FIGURE 9 in accordance with the present invention; and

FIGURE l1 is a view taken along a plane passing through line 11-11 of FIGURE 10.

In its broadest form the present invention provides method and apparatus for winding a curtain of filaments from feeder means onto a rotating drum and selectively grouping filaments of portions of the curtain to form multifilament strands. Referring to the drawings which show examples of apparatus in accordance with the present invention wherein similar reference numbers indicate similar elements in the several views, FIGURE l shows a drum 1 mounted on pedestals 18 for rotation (by means not shown) and a filament feeder 2 which is adapted to feed a curtain 3 of separated filaments to drum 1.

In the example of the figures filament feeder 2 is mounted above the downturning edge of drum 1 and is adapted to traverse a selected portion of the length of the downturning edge of drum 1 in successive reciprocatory traverses to deposit filaments of curtain 3 on drum 1 in successive overlying layers to form a condensed filamentous mat of selected thickness on the drum. Feeder 2 can be, for example, a furnace adapted to supply filaments of molten glass to an orifice plate (not shown) in the bottom of feeder 2. Filament curtain 3 is drawn from feeder 2 by rotating drum 1 and the degree of attenuation of the filaments is dependent primarily on the speed of rotation of drum 1.

In accordance with one feature of the present invention the filament collector apparatus is provided to group selected filaments of curtain 3 into multifilament strands and in the example of the present invention shown in FIGURE 1 the collector apparatus includes spaced rotatable collector cylinders 8 mounted to extend laterally from an arm 12 which is generally parallel to the longitudinal axis of drum 1. In the application as shown in the figures, where the feeder traverses a downturning edge of the rotating drum, arm 12 can be adapted to move with feeder 2 through successive reciprocatory traverses along drum 1 so collectors 8 are disposed in fixed relation relative to feeder 2. Arm 12 is attached to feeder 2 by means of support brackets 16 and 17 and, in accordance with one feature of the present invention, support bracket 16 can advantageously be adapted for pivotal movement about pivot 17a so arm 12 can be moved relatively toward and away from filament curtain 3 to move filament collectors 8 into and out of filament curtain as hereinafter described. In accordance with another feature of the present invention, as best shown in FIG- URE 3, collectors 8 can advantageously be of cylindrical shape to provide a cylindrical surface 8b for collection of filaments. Each collector 8 can have a tapered end including, for example, conical end portions 8a as shown in the figures and hemispherical end sections (not shown) to facilitate insertion of the collector into filament curtain 3 to form multilament strands 4 without breaking filaments of the curtain. Collectors 8 can, advantageously,

be made of material having a relatively low coefficient of friction to reduce abrasive action of the filaments on the surface of the collector means. For example, when glass filaments are to be wo-und on the rotating drum the collectors can be made of molded carbon.

Filament collectors 8 of the example shown in FIG- URES 1-8 are rotatably mounted on arm 12 by means of spindles 19a (FIGURE 3) which can extend through arm 12 and carry cooperative sprockets 19 at the end opposite collector 8 so the shaft can be driven at selected speed, for example by Variable speed motor 9 which can be mounted on a bracket 22 of arm 12. As can best be seen in FIGURE 4, motor 9 can also include a cooperative sprocket 23 fixed to the drive shaft and a chain 20 can be provided to connect drive sprocket 23 land driven sprockets 19 in cooperative driving relation to turn the collector wheels 8 at selected speed. Bearing means (not shown) can be provided to hold spindles 19a, sprockets 19, and collector wheels 8 in cooperative aligned relation with chain 20.

Shafts 19 can be xed to collectors 8 in aligned relation with the longitudinal axis of the collector as shown in FIGURES 3-5 so each collector 8 rotates about its longitudinal axis, or as shown in FIGURES 6-8, shafts 19 can be fixed to collectors 8 in off-center relation so each collector 8 rotates in an orbital path. In the example of FIGURE 6, line 26 passes through the longitudinal axis of the collector and line 27 is a line parallel to the line 26 passing through the point where shaft 19 is fixed to collector 8 and the `distance between lines 26 and 27 illustrates the degree of eccentricity of rotation of collector 8 when shaft 19 is rotated.

In the example of the figures, filaments are drawn from feeder 2 in the form of a curtain 3 having rectangular cross-section with a width dimension measured along the longitudinal axis of the rotating drum and a depth dimension measured in a direction generally transverse thereto. In some instances as hereinafter described it is desirable to reduce the depth of filament curtain 3 so that the filaments are wound onto rotating drum 1 as a thin curtain and, within the scope of the present invention, a collector rod 11 as shown can be provided in the filament path between arm 12 and feeder 2 to extend in a direction generally parallel to arm 12 so filament curtain 3 passes over the rod to form a relatively narrow filament curtain 3c. It has been recognized that rod 11, like collectors 8, is subject to abrasion from the filaments and the rod can be rotated to change the area of contact between'the surface of rod 11 and the filaments to evenly distribute the abrasive action of the filaments over the circumferential surface of the rod. To rotate rod 11 at selected speed a motor 13 can be provided and can be mounted on a bracket 21 fixed to arm 12. It will be noted that as feeder 2 of the example of the figures travels in first one direction and then in another direction along the downturning edge of drum 11 to change the angle of the path of the filaments relative to a transverse axis of drum 1 filaments of curtain 3 likewise move longitudinally along the rotating rod so the abrasive action of the filaments is distributed along a portion of the length of the rod.

In accordance with another feature of the present invention it will be noted, as shown in FIGURE 3, that rod 11 can be disposed relative to feeder 2 and the surface of drum 1 so filaments of curtain 3c cross the cylindrical surface of each collector 8 at an angle relative to the transverse axis of the collector and the effective area of contact (dened by the dotted lines of FIGURE 3) of the filaments of curtain 3c on the surface of rotating drum 8 is wider than the depth of filament curtain 3c. It will be noted that the width of the area of contact between the dotted lines is a function of the angle at which the filaments are drawn across the surface of collector 8 and can be selectively controlled by the position of rod 11 with respect to drum 1 and feeder 2.

The length of collectors 8 and the size of the multifilament strands gathered on the collectors are determined, in part, by the depth of the filament curtain 3c which contacts collector 8. As hereinbefore described, a collector rod can be provided to narrow the depth of the curtain of filaments and increase the number of filaments gathered into each multifilament strand. Rod 11 of FIGURE 3 can be provided to decrease the depth of filament curtain 3 so all of the filaments of curtain 3 which contact the cylindrical surface of collectors 8 are included in the multifilament strands 4. On the contrary, if a collector rod, for example rod 11, is not provided the depth of curtain 3 is substantially greater so the length of the cylindrical surface must be increased to accommodate the increased depth of the curtain and only filaments lying in the same plane are collected as multifilament strands. Therefore, in apparatus where a collector rod is not provided, several smaller, multifilament strands are formed on the surface of the collectors.

FIGURES 9-11 illustrate another example of an apparatus in accordance with the present invention which is in many respects similar to the apparatus of FIGURE 1 and similar reference numbers indicate similar elements. In the apparatus of FIGURE 9 a rotatable rod 31 is provided and includes collector wheels 32 disposed in spaced relation along collector rod 31 which are provided to selectively group filaments of curtain 3 to form multifilament strands 4. It will be noted that for a particular orifice plate configuration the number of filaments to be collected in each strand 4 is determined by the width of collector wheels 32 and that a variety of different size wheels can be used to selectively vary the size of multifilament strands 4 formed at various locations in curtainv3.

As shown in FIGURE 1l rod 31 can be disposed in the path of filaments drawn from feeder 2 to drum 1 so that the depth of filament curtain 3 is reduced in passing over rod 31 and the combined effect of the position of rod 31 and the separation of the filament curtain accomplished by wheels 32 provides separated thin curtain of filaments 3d including multifilament strands 4.

It will be noted that rod 31 is similar to collector rod 11 in that it can be rotated by means of a motor 29 joined to a bracket 21 carried by arm 12 to distribute the abrasive action of the filaments uniformly around the circumferential surface of rod 31 and collector wheels 32. The filaments of curtain 3 contact collector wheels 32 at an angle relative to the transverse axis of the wheels and it will be noted that the angular relationship between the filaments of curtain 33 and collector wheels 32 varies according to the direction in Which feeder 2 is traveling and the speed of travel.

In operation feeder 2 is driven on track 6 (by means not shown but known in the art) in successive reciprocatory traverses along the downturning edge of drum 1 and a curtain 3 of separated glass filaments is drawn from the feeder to be wound on the rotating dru-rn in overlying layers to form a condensed filamentous mat of selected thickness.

In accordance with one feature of the present invention, as illustrated schematically in FIGURES 2a and 2b which relate to the apparatus of FIGURES 1-8, a curtain 3 can be deposited on drum 1 in the form of separated filaments (FIGURE 2a) and during the formation of alternate portions of the mat collectors can be inserted into and selectively through the curtain (FIGURE 2b) to urge filaments to contiguous relation to form multifilament strands at selected locations along the width of the curtain. Further in accordance with one feature of the present invention the frequency of occurrence and distribution of such strands within the condensed mat can be controlled to provide filamentous mats having desired characteristics. As hereinbefore described, collectors 8 can be of generally cylindrical shape and can have means to facilitate insertion of the collectors into curtain 3, for example conical end sections 8a. When it is desired to form grouped filaments to be wound onto the drum arm 12 is moved toward filament curtain 3 so the apex of the conical section of each collector pierces filament curtain 3. As collectors 8 are moved further into curtain 3 increasing numbers of filaments on opposite sides of each collector are urged to contiguous relation and the size of multifilament strands 4 is increased. In accordance with one feature of the present invention, the collectors can be advanced selectively into only a portion of the curtain or entirely through the filament 3 as shown in FIGURE 3. It will be noted the number of filaments included in each strand 4 is determined by the diameter of collector 8 and the spacing between adjacent filaments drawn from feeder 2. It will further be noted that the number of filaments in strands 4 at different locations along curtain 3 can be selectively Varied by using collectors 8 of different diameter. In some applications the collectors 8 can be made very large so there is little free space between adjacent collectors and all of the filaments of curtain 3 are formed into groups so only multifilament strands are wound on drum 1.

Also, since the number of filaments in each multifilament strand varies directly with the degree of penetration of conical section 8a of collectors 8 the size of strands 4 can likewise be controlled by collecting filaments at selected locations on the conical surfaces of the collectors and regulating the penetration of the conical surface into curtain 3c to increase or decrease the size of multifilament strands 4.

Furthermore, in accordance with another feature of the present invention the collectors can be inserted through only a portion of the depth of the curtain of filaments so multifilament strands are formed in a portion of the depth of the curtain and the filaments of the remainder of the curtain is simultaneously wound on the rotating drum in separated form.

With reference to the example of collector apparatus shown in FIGURES 6-8, the present invention recognizes that if the traversing speed of feeder 2 along the downturning edge of drum 1 is substantially the same during successive traverses strands 4 will in some instances be deposited on drum 1 in overlying relation in alternate passes and result in an uneven surface where successive overlapping occurs in the areas of the condensed filamentous mat formed on drum 1. It has been found, in accordance with another feature of the present invention, that by mounting the collector wheels 8 in eccentric relation as shown in FIGURES 6-8, and by rotating the eccentrically mounted collectors in orbital paths at selected speed, strands 4 deposited on drum 1 in successive passes of feeder 2 are displaced laterally from each other so the multifilament strands are more evenly distributed across the Width of the mat and throughout the thickness of the mat. The displacement between multifilament strands of successive layers is determined by the eccentricity of the mounting, the relative speed of rotation of collector 8 and the traversing speed of feeder 2. Furthermore, it has been recognized that in some instances it is desirable to deposit the multifilament strands in the filamentous mat in a sinusoidal pattern and by proper selection of the rotating speed of collectors 8, relative to the traversing speed of feeder 2, a sinusoidal pattern of multifilament strands can be developed in the condensed mat.

In operation of the apparatus shown in FIGURES 9- 11 a collector rod 31, similar to collector rod 11 of the apparatus of FIGURE 1, is provided and includes a series of collector Wheels 32 advantageously disposed on rod 31. As shown, collector wheels 32 can have tapered edges to facilitate insertion into filament curtain 3 as arm 12 is moved toward and away from curtain 3 by means of bracket 16. As indicated in FIGURE l1, filaments drawn from feeder 2 pass over rod 31 to form a narrow curtain 3d and the filament curtain is divided `by collector Wheels 32 so that displaced filaments are urged to contiguous relation on collector wheels 32 to form multifilament strands 4.

Regardless of the particular apparatus used, filaments can be wound on rotating drum 1 in overlying layers with selectively distributed multifilament strands until a filamentous mat of selected thickness has been formed and the mat can be removed from the drum for further processing, for example by slitting the mat axially of the drum and removing it as a planar mat.

The invention claimed is:

1. A method for forming a condensed filamentous mat comprising: feeding a curtain of separated filaments from feeder means to a drum; rotating said drum about its longitudinal axis at selected speed to wind said filaments onto said drum; selectively inserting collector means having tapered end means into said curtain of filaments at selectively spaced locations along the width of said curtain so said tapered ends displace a portion of said filaments from a direct path from said feeder to said drum so displaced filaments are urged to contiguous relation on said collector means to form multifilament strands to be wound on said rotating drum; and slitting said mat axially of said drum and removing it as a planar mat.

2. The method of claim 1 wherein said displaced filaments are urged to contiguous relation on said collector means and said collector means are rotated at selected speed about an axis which is at an oblique angle to a plane passing through said filaments drawn from said feeder to said drum so the peripheral speed of the surface of said collector in the area of contact with said filaments is different than the linear speed at which said filaments are drawn over said collector.

3. Apparatus for forming condensed filamentous mat including: drum means mounted for rotation about its longitudinal axis at a selected speed; filament feeder means disposed to supply a curtain of separated filaments to be wound on said rotating drum in overlying relation; and filament collector means having converging sides defining a generally tapered end section and carried by movable arm means to selectively insert said tapered end means into said curtain of filaments at selected locations along the width of said curtain of filaments and intermediate the lends thereof, so the filament curtain is parted and filaments are displaced from a direct path from said feeder to said drum where filaments displaced by the collector are urged to contiguous relation on the surface of the collector to form multifilament strands to :be wound on said rotating drum.

4. The apparatus of claim 3 including: means to move said feeder means back and forth along said downturning edge of said drum in successive reciprocating traverses to deposit said filaments along a portion of the length of said rotating drum; and, means to move said collector means back and forth along said downturning edge of said rotating drum in successive reciprocatory traverses so said filaments and said multifilament strands are wound on said drum in successive overlying layers.

5. The apparatus of claim 3 wherein said collector means include at least two cylinders, each cylinder having generally conical-shaped converging sides defining a tapered end section; collector support means to dispose said cylinders in spaced relation so the longitudinal axis of each cylinder means is in a plane generally transverse the longitudinal axis of said rotating drum; and means to move said support means to insert said tapered end of said collector means into said curtain of filaments to a selected depth so said filaments displaced by said collector means contact a portion of the cylindrical surface of each said cylindrical collector to be urged to mutually contiguous relation.

6. The apparatus of claim 5 wherein each said cylindrical collector means is mounted for rotation on a shaft mounted in eccentric relation with the longitudinal axis of said collector means.

7. The apparatus of claim 5 wherein said collector support means is disposed to insert said rotatable collector means into said curtain of filaments so a portion of the filaments of said curtain contact the side of said collector cylinder at an angle relative to a transverse axis of said cylindrical collector means.

8. The apparatus of claim 5 wherein the diameter of one of said rotatable cylindrical collector means includes first collector means of a first diameter and at least one second collector means of a second diameter.

9. The apparatus of claim 3 including collector rod means extending generally parallel to the longitudinal axis of said drum means and disposed between said feeder and said drum means in the path of said filaments from said feeder to said rotating drum to contact at least a portion of said filaments in said curtain to narrow the depth of said curtain of filaments drawn from said feeder.

10. The apparatus of claim 9 including means to rotate said collector means about its longitudinal axis at selected speed.

11. The apparatus of claim 5 wherein said cylindrical rotatable collector means includes: rod means extending generally parallel to the longitudinal axis of said drum means and disposed in the path of a portion of said filaments from said feeder means to said rotating drum to contact at least a portion of said filaments of said filament curtain and narrow the depth of said curtain of filaments; and generally cylindrical collector wheels having tapered edge means disposed in axially aligned spaced relation among said collector rod means; and means to insert said tapered edge means of said wheel means into said curtain of filament to urge a portion of said separated filaments to contiguous relation to form multifilament strands on opposite sides of said collector wheels.

12. The apparatus of claim 10 including means to selectively move said rod into and out of said curtain of filaments.

13. The apparatus of claim 10 including means to rotate said collector rod about its longitudinal axis at selected speed.

References Cited UNITED STATES PATENTS 5/1962 Jackson 156-174 X 5/1968 Alexander 242-18 X S, LEON BASHORE, Primary Examiner R. L. LINDSAY, I R., Assistant Examiner 

